Soft Clutch, Cannot Shift (Solved)

[texdoc77]

Ok so since I have put my bike back together a few mechanical issues have reared their ugly head.  Initially I was only running on the left three cylinders.  I pulled the gas tank, re-rebuilt the petcock and now all is mostly well.  The middle header on the right side is still cooler than the other headers and so I think it might be clogged slow jets, but not sure.  Anyway not the biggest issue at this point.  So when I got it up and running I went for a quick ride.  I noted right away that the clutch lever felt soft and I really had to pull it all the way to shift and change gears.  Then  during my ride, for whatever reason, I could not pull the clutch far enough to disengage and shift gears at all.  Luckily I was in 1st gear and made it back to the house.  After a quick search on this forum some of the issues I have found that could be causing this include air in the line, worn out bushings, and worn out clutch plates.  Does this sound correct?  I do not have any tools to bleed the clutch line and I have never done that type of work before.  I do not know how hard that might be.  I also have never opened the master cylinder, again it does not sound like it is too hard, I have just never done that.  Would the way I would trouble shoot this be, 1.  Inspect replace bushing 2.  bleed clutch lever 3.  consider clutch plates?

Thanks in advance and I promise this time there is plenty of gas in the tank, LOL.

[Willow]

It does sound like it needs to be bled.  It's not a difficult task.  Go to the auto parts store and buy a Mity Vac.  The drain is directly below the nose of the saddle.  

[Fazer]

I would bleed the clutch system--sounds like you have air in the system.  Not hard to do.  Replace with new fluid.  Depending on how long, you should probably do brakes as well.  Same process. 

Lots of info if you search the forum for "bleeding brakes."

[Firefighter]

Air in the system or the bad bushing is what you will hope for at this point.

Don't know why you have air, if the bike has sat too long or if the handlebars have been upside down or what? Remove the clutch handle pivot bolt and look at the bushing to see if the hole is enlongated, if it is replace it grease and reinstall. I would also change fluid and bleed the system. Put a good tarp, towel or plastic over the tank and protect the bike from spilled brake fluid FIRST! Then remove the master cylinder cover and either pump the fluid out with the clutch lever or use the mighty vac as suggested and draw the fluid out. Stop pumping before the fluid reaches the bottom of the reservoir so as to make sure no air enters the system. Clean out the reservior with a paper towel or what ever, but soak up the fluid, then fill the reservior and continue pumping until clean fluid is seen coming from the bleeder. A couple of fills should do, then refill to full and should be done.

This is where I would start, let us know!

[texdoc77]

So I have my father in law coming over Friday evening to give me a hand with this.  We both like Arby's and I enticed him with a couple of sandwiches.  We will bleed the clutch and I will let  you know.  Big thanks to all who chimed in.  If it ends up being something else, I think I will just take it to the mechanic.

I will let you all know.

[longrider]

To speed up the process a bit after removing the clutch master cylinder cover use your wife's clean turkey baster and remove the old fluid first without moving the lever.  Add new fluid and proceed from there

[gordonv]

To speed up the process a bit after removing the clutch master cylinder cover use your wife's clean turkey baster and remove the old fluid first without moving the lever.  Add new fluid and proceed from there

Then after lunch, go out and buy a replacement baster.

[Bighead]

To speed up the process a bit after removing the clutch master cylinder cover use your wife's clean turkey baster and remove the old fluid first without moving the lever.  Add new fluid and proceed from there

Then after lunch, go out and buy a replacement baster.

[mmvalk]

suggest you consider replacing the bleeders with Speedbleeders - makes bleeding simple and quick

[pancho]

Take a look under the bike as you guys get into this txdoc, locate and look at the clutch slave cylinder to see if it has been leaking and causing your problem.  If so, it is a fix that a person can do, just need to wait on parts.

[texdoc77]

Thanks for everyone that chimed in.  It was indeed a little air in the line and about 5 minutes with a mityvac and some DOT 4 did the job.  Got some Arby's afterwards and all is well...  now about #5 not firing...

[pancho]

I may have missed a post, but I wonder how air got into the system texdoc,, did you have the hydraulic clutch apart or the master cylinder upside down?